Mechanical element and method of making same



7 April 5, 1927. 1,623,894

J. M. TAYLOR MECHANICAL ELEMENT AND METHOD OF MAKING SAME Filed Sept 11 1924 Patented Apr. 5, 1927.

UNITED STATES PATENT OFFICE.

JOHN M. TAYLOR, OF BRIDGEPORT, PENNSYLVANIA, ASSIGNOR TO DIAMOND STATE FIBRE COMPANY, OF BRIDGEPORT, PENNSYLVANIA, A CORPORATION 01 DELA- WARE.

MECHANICAL ELEMENT AND METHOD OF MAKING SAME.

Application filed September 11, 1924. Serial No. 737,171.

One object of my invention is to provide a novel form of gear, pulley or the like which shall be economical of material and easy to manufacture. I further desire to provide a practical method of making a durable, efficient, quiet running, mechanical element of the above type, such as a gear, pulley or the like, which method shall be economical and easlly carried out. A further object is to provide an externally flanged gear or pulley which may or may not also be provided with an extended hub.

These objects and other advantageous ends I attain as hereinafter set forth, reference being had to the accompanying drawings, in which:

Figure 1 is a transverse section of a pulley constructed in accordance with my 1nvention- Fi g. 2 is a sectional perspective View of one of the elements or pieces from which my device is made;

Fig. 3 is a sectional elevation through a mold showing the individual pieces, of which the mechanical element is composed, assembled within the mold, prior to the application of pressure thereto, and

Fig. 4 is a sectional elevation, similar to that shown in Fig. 3, after the application of pressure to the parts of the mold.

In carrying out my invention, I provide a series of circular elements 1 of paper, fabric, cardboard or the like, and impregnate these with a liquid phenolic condensation product in its intermediate stage, though other suitable condensation products may be employed without departing from my invention.

By suitable means forming no part of this invention, I now form or provide each disc with a flange 2 radiating from an opening at its center so that it extends outwardly parallel with and overlaps its body and alsov provide the periphery of said disc with an internally extending and overlapping flange 3.

If desired, of course, the impregnatwn of the paper, pasteboard or other sheet elements may be deferred until after they have been flanged as above described, but so far I have found this to be immaterial.

The discs made as illustrated or in form similar thereto are now placed in a relatively heavy mold in the form of a closed bottom ring 5 having at its center a suitably tapered mandrel 6 on which said discs are mounted. A plunger 7 is now introduced into the openmg of the mold which is heated: to a suitable temperature such as approximately three hundred and fifty degrees F. and the discs are subjected to a pressure of two thousand to three thousand pounds to the square inch. It will be noted that the plunger 7 has a bottom contour such as that which is desired the upper face of the pulley or gear blankshall possess, but it will be noted that the pile or stack of elements or sheets in the mold prior to the introduction of the plunger is considerably thicker in the flange portion 1 and likewise in the hub portion 1 than it is at the web portion 1, because of the flanges 2 and 3. When the plunger is forced into the mold, the various parts of the laminations assume the positions shown in Fig. 1, and when the process is completed, the resultant pulley, Wheel or gear blank has a hub and flange double the thickness of its web port-ion.

I claim:

1. A circular mechanical element having a peripheral flange, a hub; and a web connecting said hub and flange, said element being laminated and each of the laminze comprising a web-forming section together with flange and hub-forming sections ap proximately twice the thickness of said Webforming section,

2. A mechanical element made of a series of laminations each having a peripheral overlap extending radially inward and a central overlap extending radially outward.

3. A mechanical element consisting of a plurality of laminations impregnated with a phenolic condensation product in its final infusible form and held thereby to form a solid mass, said element comprising fabric sheets having. a peripheral overlap turned radially inward and a central overlap turned radially outward.

4. A mechanical element consisting of a hub, a flange and a web all made of laminations, the web comprising circular laminations, the hub comprising the inner portions of said laminations and outwardly extending portions thereof, and the flange comprising the outer parts of the lamination and portions inwardly extended.

5. The method which consists in forming a series of laminations each having a central outwardly extending overlapping portion and aperipheral inwardly extending overlap; impregnating said laminations with a phenolic condensation product; and then exposing said laminations to heat and pressure to form a mechanical element having a hub and peripheral flange, the web being half the thickness of said parts.

6. The method which consists in forming acolumn of laminations each of which condensation product in its intermediate stage; and thereafter molding said column of lamination under heat and pressure to form a circular structure.

7 The method which consists in forming a column of laminations each of which has an inwardly projecting peripheral overlap and an outwardly projecting central overlap, said laminations being impregnated with a 2 phenolic condensation product in its intermediate stage; and thereafter molding said column of lamination under heat and pressure to form a circular structure having a laterally extending flange twice the thickness of its web.

8. The method which consists in forming a column of laminations each of which has an inwardly projecting peripheral overlap and an outwardly projecting central overlap, said laminations being impregnated with a phenolic condensation product in its intermediate stage;'and thereafter molding said column of lamination under heat and pressure to form a circular structure having a 40 laterally extendin flange twice the thickness of its web and having a hub also twice the thickness of its web.

J OHN M. TAYLOR. 

